Heatless Modular Compressed Air Dryers - ENGINEERING YOUR SUCCESS - Parker Hannifin
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Compressed air contamination
is a real problem for industry
In today’s modern production facilities, the use of compressed
air is often pivotal to manufacturing processes. Irrespective of
whether the compressed air comes into direct contact with the
product or is used to automate a process, provide motive power,
or even to generate other gases on-site, a clean, dry, reliable
compressed air supply is essential to maintain efficient and cost
effective production.
Parker provides complete
compressed air treatment solutions to suit every industry,
application & budget.
The benefits of using Parker compressed air treatment solutions:
• Plant Reliability - trouble free operation from equipment and processes using
compressed air
• Clean Dry Air available for all applications
• No contamination of products / processes / equipment
• Low Maintenance Costs – Reduce or eliminate unexpected / unplanned
plant maintenance for better budget control
• Lower plant energy consumption
• Lower plant environmental impact
• Legislation compliance – e.g. assist in complying with
hygiene legislation in the Food, Beverage & Pharmaceutical industries
1Compressed air dryers – The heart
of the compressed air treatment solution
At the heart of any compressed air treatment solution is the dryer, it’s
purpose, to remove water vapour, stop condensation, corrosion and in
the case of adsorption dryers, inhibit the growth of micro-organisms.
Heatless adsorption dryers (also known as PSA dryers) the only viable technology available. Additionally,
are the simplest type of adsorption dryer available and modular heatless dryers provide an even more reliable,
have long been the dryer of choice for many industries smaller, more compact & lightweight dryer which can be
and applications. They are simple, reliable and cost installed in both the compressor room or at the point of
effective and for small to medium flow systems, often use.
Benefits of Heatless Adsorption Dryers
• Industry proven design • Robust & reliable
• Suitable for all industries and • Uses clean, dry compressed air for
applications - some adsorption dryer regeneration making them suitable for all
regeneration methods prevent their use industries and applications
in certain industries / applications
• Lower maintenance costs compared
• Lower capital investment compared to to other adsorption dryer regeneration
other adsorption dryer regeneration methods
methods
• No heat / heaters / heat related issues
• Reduced complexity compared to other
• No process air required for cooling
adsorption dryer regeneration methods
RELIABILITY QUALITY EFFICIENCY
2Parker Heatless Modular Dryers
Using advanced aluminium extrusions, Parker has developed
a desiccant dryer ranges that are smaller, more compact and
lightweight comparied to conventional fabricated steel designs.
These advanced desiccant dryers include ranges of extruded aluminium columns and manifolds, the
small flow, medium fow and large flow heatless modular design eliminates the need for complex
modular dryers which provide one of the most valves or interconnecting piping.
simple and cost effective compressed air drying Also, the length to diameter ratio of the internal
solutions. voids and non-welded construction means that
Engineers at Parker have developed each range Parker modular aluminium dryers do not require
using innovative aluminium forming technology, periodic inspections for insurance purposes, unlike
resulting in units that are smaller, more compact traditional welded steel dryers that need to be taken
and lightweight compared to conventional welded out of service for inspection, which can severely
steel desiccant air dryers. Using high tensile disrupt production schedules.
Drying Columns Distribution Manifold
Greater flexibility with multi-banking
Multi-banking
Unlike traditional twin tower dryer
designs, MX & MXLE models can
be multi-banked to provide extra
compressed air drying capacity.
Should demand increase in the
future, there is no need to replace the
dryer with a larger unit, additional
capacity can be covered by simply
adding extra dryer modules (banks).
Flexibility
Multi-banking allows individual dryer
banks to be easily isolated for routine
service work, whilst maintaining your Fits through a standard
clean, dry air supply.
doorway
100% stand-by Unlike traditional twin tower designs,
Compared to traditional twin tower modular dryers will fit through a
designs, 100% standby is available at standard doorway, eliminating the
a fraction of the cost as only one extra need for special access or facility
dryer bank is required. structural dismantling during
installation.
3Parker Heatless Modular Dryers - Four Key
Features to Guarantee Air Quality
OIL-X Filtration
Adsorption dryers are designed only for the reduction of water vapour and not liquid
water, liquid oil, water aerosols, oil aerosols, particulates or micro-organisms. Only by
using Parker OIL-X pre and after filtration can the treatment of these contaminants be
assured and air quality in accordance with all editions of ISO8573-1 be guaranteed.
Modular aluminium design
Aluminium extrusions are used throughout for drying chambers and
distribution manifolds. This design not only alows the dryer to be smaller,
more compact and lightweight, it allows the adsorbent desiccant material to
be filled using a speciallist technique called 'Snowstorm' filling which achieves
maximum packing density of the deisccant material (more adsorbent in a
smaller space).
Adsorbent desiccant material
Specially selected desiccant materials provide:
• Optimum adsorption and regeneration capacity - to ensure consistent dewpoint
• Low dusting - to prevent blockage of downstream filtration
• High crush strength - to prevent breakdown of the desiccant during operation
• High resistance to aggressive and oil-free condensate - for compatibility
with all types of air compressor, their lubricants and condensate
Snowstorm filled bed 'Snowstorm' filling method
Parker modular dryers use the 'Snowstorm filling' method
to fill the drying columns (or desiccant cartridges) with
adsorbent desiccant material.
Snowstorm filling:
• Achieves maximum packing density for the desiccant
material, fully utilising all of the available space
envelope
Consistent drying with • Prevents compressed air channelling through the
no desiccant attrition desiccant as experienced with twin tower designs. Due
to channelling, twin tower designs require more
Loose filled bed desiccant to achieve an identical dewpoint, increasing
physical size, operational and maintenance costs
• Prevents desiccant attrition which can lead
to dusting, blocked filters and loss of dewpoint
• Allows 100% of the available desiccant material to
Maximum Packing Density be used for drying, therefore reducing the amount
'Snowstorm' filling of desiccant required and maintenance costs
ensures consistent
dewpoint performance • 100% of the desiccant is regenerated ensuring
Inconsistent drying and consistent dewpoint
desiccant attrition
• Provides a low, equal resistance to air flow allowing
multiple drying chambers and multiple dryer banks to
be used (MX & MXLE ranges)
4Heatless modular compressed air dryers -
a dedicated solution for every application
By combining the proven benefits of desiccant drying with modern
design, Parker has produced an extremely compact and reliable
purification system to totally dry and clean compressed air.
The Parker ranges of small, medium and large flow heatless modular dryers have proven to be the ideal solution
for many thousands of compressed air users worldwide in a wide variety of industries.
Compressed air purification equipment must deliver uncompromising performance and reliability whilst
providing the right balance of air quality with the lowest cost of operation.
Benefits:
• Highest quality air
- Clean, dry, oil-free compressed air in accordance with all editions of ISO8573-1, the international
standard for compressed air quality
• Energy efficient
- Energy Saving Technologies fitted as standard to all medium and large flow models
- Optional for small flow models
• Dry air eliminates microbiological growth
- Preventing product spoilage, recall and litigation
• Dry air means zero corrosion
- Preventing product spoilage and damage
• Smaller, more compact and lightweight
- Modular construction means less than half the size of conventional dryers
• Modular design
- 100% standby at a fraction of the cost of twin tower designs
- 10 year guarantee on pressure envelope
- Corrosion resistance due to alochroming and epoxy painting
- Constant dewpoint performance thanks to snowstorm filling
• Approvals to international standards
- PED, CE, CSA (US+Canada), CRN
• Easy and flexible installation
- Minimal space required
• Simple maintenance
- Giving reduced downtime
• Reduced noise pollution
- Super quiet operation
Clean, dry compressed air improves production efficiency and reduces maintenance costs and
downtime. Only an adsorption dryer can provide the highest levels of dry compressed air in
accordance with ISO8573-1:2010, the International Standard for Compressed Air Purity (Quality).
5Parker Heatless Modular Compressed Air
Dryer Ranges
Small Flow Dryers
0.13 to 1.43 m³/min / 8 to 86 m³/hr / 5 to 51 cfm @ 7 bar g (102 psi g), 35°C (77°F)
K-MT 1-8 KA-MT 1-8
Medium Flow Dryers
0.92 to 5.01 m³/min / 55 to 300 m³/hr / 32 to 177 cfm @ 7 bar g (102 psi g), 35°C (77°F)
CDAS HL 050-085 OFAS HL 050-085 FBP HL 050-085 CDAS HL ATEX050-085
Large Flow Dryers
Single Banks 6.81 to 34 m³/min / 408 to 2040 m³/hr / 240 to 1200 cfm
Multi Banks >35 m³/min / >2041m³/hr / >1201cfm @ 7 bar g (102 psi g), 35°C (77°F)
MXS102CDS-MXS108DS MXLE102C-MXLE108 MXP102C-MXP108
6Heatless Modular Dryer - Operation
Adsorption dryers work on the principle of moisture always
migrating to the driest medium possible. Therefore, water
vapour is removed from compressed air by passing it over
an adsorbent desiccant material.
As the compressed air contacts the adsorbent At any one time, whilst one chamber is on-line,
material, water vapour transfers from the wet air drying the incoming compressed air, the other
to the dry desiccant material. Adsorbent materials is either off-line, being regenerated or is re-
have a fixed adsorption capacity and once this pressurised, ready to come on-line. All adsorption
capacity is reached, they must be regenerated or dryers treat water vapour in this manner.
replaced.
The energy consumed by an adsorption dryer
Therefore, to provide a continuous supply of can be directly attributed to the method used to
clean, dry compressed air, adsorbent dryers regenerate the adsorbent material.
utilise two chambers of desiccant material.
Heatless Modular Dryer Operation - Drying Cycle
The pre-filtered process air enters the dryer through the inlet and is directed into the on-line drying
chamber via the inlet valves.
(Modular models can be made up of either single or multiple drying columns, depending upon the range)
The compressed air is evenly distributed through the drying columns and passes over the adsorbent
desiccant material, reducing the water vapour content of the compressed air as it contacts the desiccant.
The dried process air then exits the dryer via the outlet check valves.
Dry Compressed Air
Desiccant Bead
Wet Compressed Air
MX Dryer used for illustration purposes, all heatless adsorption dryers operate in an identical manner
7Heatless Modular Operation - Regeneration Cycle
At the start of the regeneration cycle, the exhaust valve of the dryer is closed and the off-line chamber is at full line
pressure. The air in the off-line chamber has a dewpoint equal to the air leaving the dryer.
The exhaust valve is then opened and the dry air within the chamber expands rapidly as it leaves the dryer via the
exhaust silencer, forcing water to be removed from the desiccant material.
Once the off-line chamber has depressurised, a continuous bleed of dried process air is directed into the off-line
desiccant bed for regeneration purposes. This regeneration air is also known as purge air.
With the exhaust valve open, the purge air expands from line pressure to atmospheric pressure and flows
downwards over the off-line desiccant material.
As the purge air at line pressure contains a fixed amount of water vapour, allowing it to expand means the purge air
becomes even drier, increasing its capacity to remove water from the saturated desiccant bed.
Dry Purge
Air
Desiccant Bead
Wet Purge
Air to Atmosphere
Heatless Modular Operation - Column Changeover
Before the on-line (drying) and off-line (regenerating) columns change over, the dryer exhaust valve, is
closed, allowing the purge air to repressurise the off -line columns. This ensures a consistent downstream
pressure and dewpoint when the drying chambers change over.
Standard Heatless Drying & Regeneration Cycle
Time
(minutes)
changeover
changeover
0 2.5 3 0 2.5 3
Side A Regeneration Re-pressurisation Drying
Side B Drying Regeneration Re-pressurisation
8Heatless Modular Dryers - EST & DS Energy
Saving Technologies
The energy required to regenerate the off-line desiccant bed in an
absorption dryer is constant, and based upon the assumption that the
dryer is operating at its full capacity and the desiccant bed requiring
regeneration has been fully saturated.
In reality, a dryer is rarely operating at full capacity all of the time,
for example during shift work and periods of low demand. Daily and
seasonal fluctuations in ambient temperature and humidity also change
the moisture loading placed upon the dryer.
Under such conditions, at the point in the drying cycle where the air flow
is switched from one drying chamber to the other, there is the potential
for drying capacity to remain in the desiccant material about to undergo
regeneration. As the energy used to regenerate this partially saturated
bed is based upon the assumption that the bed is fully saturated, more
energy (purge air) is consumed than is actually necessary.
20
AVERAGE MAXIMUM DAILY TEMPERATURE
ENERGY SAVINGS IN
Proportional Energy Usage THESE PERIODS
The Parker EST / DS - Energy Saving Technologies 15
ensure the energy consumed by the dryer is directly
proportional to the amount of water vapour present
10
and not the dryers maximum rated capacity.
5
0
MONTH
Example of % energy savings available with the EST / DS Technologies
The following example highlights the percentage energy savings available with EST / DS Energy Saving
Technologies in operation.
% Saving Energy Savings Available with EST & DS Energy
% Flow 35 °C 30 °C 25 °C 20 °C 15 °C 10 °C Saving Technologies
% Energy Savings
100 14 % 35 % 52 % 65 % 74 % 81 % 100
80
90 23 % 42 % 57 % 68 % 77 % 83 % 60
40
80 31 % 48 % 62 % 72 % 79 % 85 % 20
0
70 40 % 55 % 66 % 75 % 82 % 87 % 100 90 80 70 60 50
% of Maximum Inlet Flow Rate
60 49 % 61 % 71 % 79 % 85 % 89 %
50 57 % 68 % 76 % 82 % 87 % 91 % 35 °C 30 °C 25 °C 20 °C 15 °C 10 °C
Example based upon a CDAS HL 075 / OFAS HL 075 Purification System and referenced to a 3 Minute Standard
Cycle. Energy savings are applicable to all CDAS / OFAS / FBP / MXS-DS / MXLE models.
Sizing Conditions : Min System pressure: 6.5 bar g / Max Inlet Temp: 35°C / Max System flow: 180 m3/hr
Average Conditions : Inlet pressure: 7.5 bar g / Average Temp: 10°C - 35°C / Average Flow: 50% - 100%
9EST & DS Energy Saving Technologies
Operation
Parker CDAS / OFAS / FBP / MXS-DS / MXLE dryer ranges are all fitted as
standard with either the EST or DS Energy Saving Technologies (optional
for K-MT & KA-MT ranges). With these installed, the drying cycle remains
unchanged, however as the drying chambers are about to change over, the
EST / DS energy saving technology overrides normal operation to fully utilise
the drying capacity of the on-line desiccant material.
EST & DS Energy Saving Drying Cycle Extension
At the end of the regeneration cycle, and prior to column changeover,
the exhaust valve is closed to allow the purge air to re-pressurise the off-
line column, thus ensuring no loss of system pressure on changeover.
After re-pressurisation, both drying chambers will be at full line pres-
sure, no purge air is being used for regeneration and the dryer is in a
state of zero energy consumption.
Under normal operation, the drying chambers would now proceed to
change over automatically, however the EST / DS energy saving tech-
nologies incorporate a dewpoint sensor which is used to monitor the
pressure dewpoint of the compressed air leaving the dryer.
If the compressed air dewpoint is lower than the pre-set minimum dew-
point, the desiccant material is only partially saturated and has drying
capacity remaining within it.
The EST / DS energy saving technology will therefore override the stand-
ard control cycle and the dryer will continue to dry on the same column
with zero energy consumption for regeneration.
The dewpoint sensor constantly monitors the outlet pressure dewpoint
until the minimum set dewpoint has been achieved, at which point, col-
umn change over will occur.
The drying and regenerating cycle will then continue normally until the
next column changeover when the EST / DS energy saving technology
may again extend the drying cycle as dictated by the outlet pressure
dewpoint.
During the extension of the drying cycle, no purge air is consumed, sav-
ing compressed air, saving energy and saving money.
EST / DS Operation - Energy Saving Drying Cycle Extension
Heatless Dryer Fitted with EST or DS - Drying & Regeneration Cycle
Time changeover changeover
(minutes) time dictated time dictated
0 2.5 3 0 2.5 3
by outlet by outlet
changeover
changeover
dewpoint dewpoint
Side A Regeneration Re-pressurisation Energy Saving Drying
Side B Drying Regeneration Re-pressurisation Energy Saving
10Dryer Positioning
The preferred installation for any compressed air dryer Installing downstream of the air receiver is not always
is downstream of a wet air receiver as the air receiver possible or desired (for example some installations
not only stores compressed air, it actually reduces the require a store of clean dry air) and Parker heatless
temperature of the compressed air slightly and can modular dryers can also be installed prior to an air
help reduce “excessive peaks” in moisture loading receiver.
should they inadvertently occur.
Additional Energy Savings
Called Purge Economy, it is an energy saving feature
For installations where a Parker modular dryer is for Parker heatless dryers where the dryer is placed
installed between the air compressor and the air directly after the compressor and before the air
reciever, an additional energy saving feature built into receiver
the controller can also be implemented.
A Typical Installation
In a typical installation, the compressor will use a
pressure switch connected to the air receiver to sense
the system pressure.
When system pressure is achieved, the compressor
goes off load. If there is no system demand, i.e.
evenings and weekends, in theory the compressor
should remain off load, using no energy.
11Air loss
In this installation, even though there is no system
demand and the compressor is off load, the dryer will
continue to cycle, using purge air to regenerate the off-
line column.
As the dryer purges the off-line column, it will slowly
reduce the system pressure, eventually dropping to a
point where the compressor will come back on-load to
maintain pressure.
Purge Economy Operation
Purge economy is designed to stop the dryer
regeneration cycle when the compressor goes off load.
It uses a signal from the compressor to stop the dryer
regeneration cycle and close the exhaust valve. This
prevents unnecessary use of purge air, saving energy &
money. Once the system pressure drops due to actual
air demand, the compressor re-starts and the normal
drying cycle will be resumed.
Built in Dewpoint Protection for EST or DS Equipped Dryers
In certain geographical locations, a dryer can be Therefore Parker EST & DS Energy Saving Technologies
operated for extended periods with low amounts also incorporates a safety feature to protect the
of water vapour in the inlet air (for example, some desiccant material. The safety feature, called Moisture
countries can have an ambient temperature up to +40 Override activates after 30 minutes, interrupting
°C in summer and as low as -40 °C in winter). the energy saving function and changing the drying
columns over. This allows a full regeneration cycle of
As the dryer must be sized for summer conditions, the desiccant material to take place before going back
during winter, months, the EST or DS – Energy Saving into energy saving mode. Now energy savings can be
Technologies will save the user air, energy & money. realised without causing the desiccant bed to become
However, due to the way a desiccant bed adsorbs over saturated.
water vapour, during winter months with low levels
of water vapour in the incoming air, the saturation
profile of the desiccant bed changes and a condition
may occur where the bed becomes too saturated to be
regenerated by the standard purge regeneration cycle.
12Compressed Air Treatment for
Food, Beverage and Pharmaceutical Use
Parker OIL-X filter range and Parker modular adsorption dryer ranges have been
designed to provide compressed air quality that meets or exceeds the levels
shown in all editions of ISO8573-1, the international standard for compressed air
quality and the BCAS Food and Beverage Grade Compressed Air Best Practice
Guideline 102.
Filtration & dryer performance has also been independently verified by Lloyds Register.
Water Separators Oil Vapour Reduction Filters
Water separator performance has been tested in Oil vapour removal filter performance has been tested
accordance with ISO12500-4 and ISO8573-9. in accordance with ISO8573-5.
Coalescing Filters Heatless Adsorption Dryers
Coalescing filter performance has been tested FBP HL, MX & MXLE dryer performance has been
in accordance with ISO12500-1, ISO8573-2 and tested in accordance with of ISO7183
ISO8573-4.
Dry Particulate Filters
Dry particulate filter performance has been tested in
accordance with ISO8573-4.
In addition to performance validation, the materials used in the construction of the ranges
recommended below for use in food, beverage & pharmaceutical manufacturing are FDA
Title 21 Compliant and EC1935-2004 exempt. Certificates available on request.
Recommended Dryer Ranges for Food, Beverage & Pharmaceutical Grade
Compressed Air
FBP Oil Free Air System MX Adsorption Dryer MXLE Low Energy Adsorption Dryer
13Compressed Air Treatment for Hazardous
Environments
Oil & Gas Drilling and Production Installations can installations. Products must be rugged, reliable,
be some of the most inhospitable working areas high strength, compact and be able to withstand
known to man. Apart from potentially explosive salt-water corrosion while still being able to
and corrosive areas, ambient temperatures can function as specified.
vary from -20°C to 50°C with wind speeds of up
Maintaining safe operations in a hazardous
to 80mph and the constant battering from high
working environment means a reliance on motive
waves, an oil rig is a demanding place for man or
and instrument quality compressed air. In a dirty,
machine.
humid and corrosive atmosphere this must be
The highest equipment specifications are therefore consistently clean and dry in order that system
required for Oil & Gas Drilling and Production quality and safety is not compromised.
Installations that dictate a quality of design and
manufacture seldom required for conventional
Fully Pneumatic Operation & ATEX Compliant
In addition to providing air treatment products for standard
industrial applications, Parker also specialises in the design and
manufacture of compressed purification equipment for hazardous
industries such as chemical/petrochemical and offshore oil & gas.
Parker can supply fully pneumatic ATEX versions of their medium
flow compressed air dryes (CDAS HL ATEX ) and high flow
compressed air dryers (MXP ATEX) which are fully compliant with
ATEX Directive 2104/34/EU Group II, Category 2 GD and 3rd Party
Certified.
14Parker Worldwide
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